Process for making artificial stone and the stone.



.l'lA'RRY O. DUERR, F WILMINGTON, DELAWARE.

PRUGESS FOR MAKING ARTIFI GEAL ETGNE AND THE STQN E.

No. erases.

Specification of Letters Patent.

Eatented Dec. 17,

Application filed October 29s 1907. $crial No. 399K752,

- useful improvements in Processes for Making Artificial Stone and theStone, oil which the following is a full, clear, and exactspeciligation. I

The ii yention or discovery herein described has for its object theproduction of such artificial stone as will possess all the qualities ofnatural stone, i. a, strength, texture, durability, impermcability andcolor. At the same time I have sought to produce a product that iscapable of being dressed and otherwise treated as natural stone andwhich shall contain no ingredients-which the action of weather or timesh all tend to disintegrate, disrupt, discolor, or be injurious to theproduct.

in preparation for the manufacture of the herein described product thefollowing materials or ingredients are selected:

1. A quantity of suitable silicious material, silica, or sand.

A properly burned high calcium lime or l ydrauli'c lime.

A suitable cement constant in volume, that is, one that will pass theaccelerated lost for soundness as specified by the American Society for'i est-ing h'lateriul. The function of the cement is to serve as atemporary binder, holding together the ingredients until the silicationin the steam chamber has proceeded to a sull'ici'ent degree to insurecoherence in the block. it seems probable that the cement, which ispreferably of a silicious character, as indicated above, itsell aiiectedby the steam treatment and becomes more or less completely united withand made a part of the calcium silicate led from the union of the limeand finely divided sand. 'lhat is, l have i believe to some c:rtent atleast a single binder in effect, though one complex in character, andnot a simple dual binder formed by the mere adding together of twoprimary binders. 1 prefor a quick setting cement.

In carrying out my process various combinations maybe made with theingredients above mentioned and 'substantially the same product willresult therefrom.

Inasmuch as dilierent cements are characled by dille ant shades ofcolor, maniwhen dnlerent cements are used, dd-

ferent effects in the product will result so I as the color isconcerned.

In order to produce my product I am genorally obliged to grind all orpart of the silicious material, silica, or sand, sufficiently ijine sothat all or most of the voids in the composite mass are filled. Ofcourse if the silicious material, silica, or sand used, in its naturalstate, is fine enough to accomplish the cndabove set forth, thengrinding will,

not be necessary.

Besides filling the voids as above described, the finely dividedsilicious material, silica, or-sand performs the additional importantfunction of increasing the facility of the chemical or indurating actionwhich takes place in the curing process.

Having thus described the ingredients which enter into my product, Iwill now describe the method by which I carry outmy process.

Preferably l first roast a quantity of -silicious material, silica, orsand, quenching this material with water as it comes from the roaster.This is done for the purpose of making the silicious materiel, silica,or sand into a more amorphous state thereby facilitating the chemicalaction- Then I grind the material roasted and lime together.- If thelime is unhydrated I add sufficient water to the product to chemicallyhydrate the lime, seasoning the mixture in b ns or silosfor asufiicient'"lerigth of time to complete the hydration. After thehydration, cement is added to this product and round. To'thisground-mixture is then a ded coarser silicious material,'silica, orsand, and then the compound. is rendered plastic by the addition ofsuflicient water to render it capable of being molded: It may then bemolded in any suitable way to any desired form after which it is curedby subjecting it to the action of steam under pressure in any suitablemanner.

The prooortions of ingredients used in the formula a eve describedvaries somewhat with the results sought and the special requirements ofeach case. be said that the proportions of silicious material, silica,or sand, and lime used should be such that when ground, mixed togetherand then combined with water and cured, there will be produced a perfectproduct of sili oates of lime, in practice I have found thatsubstantially this result may be insured by usin about two (2) parts ofsilica to one (1) In general it may part of lime. To the above mixturemay then be added approximately one (Ilfiartfof cement and six (6) partsof silicious material, silica, orsand. The relative proportions of thesei edients will yary however according to t e coarseness of the ungroundsilicious material, silica,'or sand, the object be.'

mg in allcases to fill the voids existin in the silicious material,silica, or sand. 0 by varying the proportions and kinds of cement used,many varieties of product will result which will differ intexture,quality, color and appearance.

I do not intend to confine myself to the above proportions or mixture asthese must be'varied to suit local conditions of materials to be usedand results sought for.

sand; Thus the roastin The vhereinbeiore described preferable method bywhich I carry out my process may ,be departed from in the followingparticulars without substantially affecting the result produceddepending somewhat upon the character of the silicious material, silica,or of siliciousniaterial, silica, or sand, may e omitted entirely; orthe grinding of the mixture'of lime, silicious material, silica, orsand, and cement may be omitted. Or the silicious material, silica, orsand, may be ground separately; then mixed with quicklime and themixture hydrated-after which the process proceeds as above set forth. Orthe lime may first be hydrated; then mixed with silicious material,

silica, or sand, and the mixture ground after which the process roceedsas described. .Or

' ,the lime may first e hydrated; then the silisilicious. material,silica, or sand, or the lime may be mixedwith' the unground silicious,

material, silica, or sand, and, the'mixture hydrated after which theprocess proceeds", as'

hereinbefore described.

It is obviousl impossible to set forth herein all the ossi 1e variationswhich ma be made in t e proportions of the ingredients used, for myprocess or the exactqualit of the cement used, orthe exact degree ofneness re uire'd for the silicious material, silica, or san and cementbut all these matters must be determined by him who is skilled in theart in accordance with the requirements of the article it is desired toproduce.

D In several of the claims herein I have set forth as an element of myprocess the by dration of said mixture or hydrating said mixture. It isto be und rstoed that this stee of my process isneces ary on] in caseun. ydrated lime 13 used and it ml be like forth.

erases wise clear that if hydrated lime be used this stefl of my rocesswill not be necessary.

aving t us described my invention what I claim'is:

1. The process of making artificial stone coin rising the roasting ofsilicious material; 'ng said roasted material with lime the y d rationof said mixture; grinding said,

said ground mixture with a coarser silicious material; adding sufficientwater to said compound to render it plastic; molding it to any desiredform, and then sub'ec'ting it to an indurating action, substantially asset forth.

2. The process of making artificial stone comprising the mixm of finelydivided silicious material with lime; the hydratin of said mixture;mixing said mixture wit a coarse silicious material and a cement; addingsuflicient water to said compound to render it plastic; molding it toany desired form, and then subjecting it to the action of steam underpressure, substantiallyas set forth; v

3. The process of making artificial stone com rising the grindin ofsilicious material and ime together; hydrating said mixture;

mixing the product with a coarser silicious material and a cement;adding sufficient water to render the com ound plastic; moldin it to anydesired orm, and then subjecting it to the action of steam underpressure, substantially as set forth.

4. The process of making artificial stone comprising the roasting ofsilica;

said roasted silica with lime; the hydration of said mixture; grindingsaid mixture with cement; mixing said ground mixture with a coarsersilica; addingsufiicient water tosaid compound torender it plastic;molding it to any desired form, and then subjectin it to the action ofsteam under tially as set forth.

5. The process of making artificial stone comprising the mixing offinely divided silica pressure, su stan-v with lime; the hydrating ofsaid mixture;

mixing said mixture with a coarser silica and any desired form, and thensubjectin it to the action of steam under pressure, 511 stan- 'tially asset forth.

gather; hydrating sai mixture; mixing the af'e'ement; addin 'sufiicientWater to said compound to .ren er it plastic molding it to product witha coarse silica and .a cement;

addin sufiicienthwater to render the comoun plastic; molding it to anydesired orm, and then subjecting it to the action of steam underpressure, substantially as set 7. The process of makin artificial stonecomprising the roasting o sand; grindin said roasted sand with lime; thehydration 0 said mixture; grinding said mixture with emen;

cement; mixing said ground mixture with a coarser sand; addingsufiicient Waterto said compound to render it plastic; molding it to anydesired form, and then subjectin it to the action of steam underpressure,su stantially as set forth.

8. The process of making artificial stonecomprising the mixing of finelydivided sand with lime the hydrating of said .mixture;-

mixing said mixture With a coarser sand and a cement; "adding sufiicientwater to said compound to render it plastic; molding it to any desiredform, and then subjecting it to the action of steam under pressure,substan- H tially as set forth.

9. T he process of making artificial stone comprising the grinding ofsand andv lime together; hydrating said mixture; mixingthe product witha coarser sand and a cement;

adding sufficient Water to render the comound plastic; molding it to anydesired i'orm, and then subjecting it to an indurating action,substantially as set forth.

10. An artificial stone composed of a calcium silicate'formed by theunionof a finely divided silicious material and lime, a coarsersilicious material in such quantity that the voids thereof aresubstantlally filled by the components of the calcium silicate and asuitable cement, substantially as described.

11. An, artificial stone composed of a calcium silicate formed by theunion of a finely divided silica and lime, a coarser silica in r suchquantity that the voids thereof are substantially filled by the comonents of the calcium silicate and a suitab e cement, substantially asdescribed. I

12. An artificial stone composed of a calcium silicate formed by theunion of a finely JOHN WHITE, Jr.

